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CONTINOOUS REGENERATIVE GAS-KILN 


FOR 


RNING FIRE- 





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m 


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E.u, 


THOMAS EGLESTON, Ph.D. 

NEW YORK. 


Read before the American Institute of Mining Engineers, 
AT THE St. Louis Meeting, October, 1886. 



PRINTED FOR THE AUTHOR. 
1886. 
































































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1 



THE DUNNACHIE CONTINUOUS REGENERATIVE GAS- 
KILN FOR BURNING FIRE-BRICK, POTTERY, ETC. 


BY THOMAS EGLESTON, PH.D., NEW YORK CITY. 



})ottery, etc., has been delayed beyond what won Id naturally have 
been expected, because there has been until recently little necessity for 
high heat in burning such material. But the introduction of pro¬ 
cesses using very high heats, like the open-hearth steel and the basic 
processes, has required special attention to be paid to fire-bricks. It 
has become necessary not only to have the bricks of a much better 
quality, but also to have them burned at a much higher temperature 
than formerly. It has been found that if bricks burned at a low 
t^iiperature are submitted, in the process in which they are to be 
used, to a higher temperature than that at which they were burned 
they are likely to undergo considerable change. It has also been 
found that in burning these bricks in the old way, serious difficul¬ 
ties arise from the introduction of the ashes of the fuel into the brick. 
To avoid this evil, gas was first employed; but the regenerative sys¬ 
tem has not been used until recently. It is quite plain from the 
outset that the regenerative system as it is applied to the ordinary 
furnace, that is, having the products of combustion passed through a 
checker-work, whether by the non-continuous or the continuous sys¬ 
tem of regeneration, would not be applicable to the burning of such 
material as pottery and brick, even though the fire-brick should 
command a high price in the market. Any system, to be successful, 
must accomplish two things: first, regenerate the heat; and, secondly, 
use for the regeneration, the heat contained in the material itself 
which is being manufactured. One of the greatest sources of waste 
of fuel in metallurgical operations is due to the considerable quantity 
of heat wasted, by being taken out with the material which has been 
burned, when it leaves the furnace. A serious loss of heat in burning 
[)ottery and bricks is incurred while the bricks which have been fully 
burned are waiting in the furnace to become cool enough for removal. 
If this heat could be stored up and used in the process, so that the heat 


/ 




2 THE DUNNACJIIE GAS-KIEN FOR BURNING FIRE-BRICK, ETC. 


contained In the articles being manufactured wonld lie so thoroughly 
utilized that when the furnace was ready to be discharged, the arti¬ 
cles would be very nearly cold, there would be a very great gain. 
It might be objected that the time lost and the consequent diminu¬ 
tion of output wonld more than counterbalance the fuel saved. 
This, however, has not proved true in the working out of the pro¬ 
cess by the few furnaces that have been invented to accomplish 
this object effectually. To secure the best results, it is not only 
necessary that a cheap fuel should be used, but that all of it should 
be burned and turned to commercial account in the course of the opera¬ 
tion. There are comparatively few cases where this principle of heat 
regeneration by means of abstracting the heat from the article man¬ 
ufactured has been applied. It will undoubtedly have a much 
further extension, and Its application will be of the greatest interest to 
manufacturers.. 

The successful a[)plication of the regenerative principle to brick¬ 
making involves several conditions. One of these is that the radiation 
of heat from the outside of the furnace should be used for some pur- 
})ose or reduced to a minimum, or entirely prevented. Another is, 
that the combustible gases should be consumed at the point where tljg 
temperature is required to be highest, and that the temperature in 
the chimney, where the gases are discharged from the furnace, should 
be only sufficient to produce the draft necessary to carry them off. 
Several persons have turned their attention to the subject of regen¬ 
erative kilns for burning fire brick. One of the most successful of 
these is Mr. Jas. Dunnachie, of Glasgow, who, in September, 1881, 
introduced his furnace at the Glenboig Fire-brick Works, near Glas¬ 
gow, and subsequently in several other places. The old-fashioned 
Newcastle kiln shown in Plate I., was formerly used at Glenboig, 
and is still in operation there, owing to the fact that a number of 
kilns of this type were in good order at the time the regenerative 
kiln was started, and have not since been torn down ; but they do 
not burn as economically as the latter. 


The Dunnachie kiln consists of a series of ten chambers arranged 
five in a row, connected with each other by underground flues. In 
Plate II. these chambers are shown with a flat arch, but they are 
usually built hemispherical. The arrangement of these kilns is 
shown on the ground plan. Fig. 1., Plate II., and in sections 2 
and 4 to 7. The chambers are numbered 1 to 5 on one side, and 
6 to 10 on the other. The distances between the two sets of fiv'^e 
chambers is 20 feet. This space and the whole top of the kiln is 


[To accompany Prof. Egleston’s Paper on the Dunnachie Kiln.] 


PLATE I-THE NEWCASTLE KILN. 


A—Side walls. 

B—Back walls between the kiln and the flue. 
C—Kiln chambers. 

D—Arch over the kilns. 

E—Front wall. 

F—Buttresses to sustain the kiln. 

G—Arch between the two kilns. 

H—Ash-pit outside of the kiln. 

I—Door of the fire-place, counter-poised. 

J—Opening for picking the fire. 

K—Door of the kiln. 

L—Openings in the roof. 


PLATE II.-THE DUNNACHIE KILN. 


A—Gas-valves controlling the gas going to the kilns. 

B—Producers. 

C—Chimnev-flues. 

ml 

D—Side-flues leading to chimney-flues. 

E —Main gas-flue. 

F—Gas-valves from main to the kilns. 

G—Opening admitting air to the floor of the kiln. 

H—Kiln-doors. 

I—Outside opening to hot-air flue O on the floor of the kiln. 

J—Flue connecting chambers 1 and 10. 

K—Spy-hole for the inspection of the kiln and for taking off* hot air 
L—Flue conveying hot or cold air to upper part of the kiln. 

M—Flue connecting chambers 5 and 6. 

N—Hot-air opening from one kiln to the other. 

O—Flue bringing hot air from kiln to burn gas in the next kiln. 

P—Underground flue bringing hot air to O. 

Q—Flue bringing gas from R into the kilns. 

R—Main gas-flue to kilns, a continuation of E. 

S—Lower flue for hot air. 

T—Outside opening into the flue L. 

a—Slits between the flues for passage of air. 

b—Openings for passage of gas. 

d—Slabs of fire-clay, closing openings in roof. 

e—Fire-clay slab, cutting off hot air from the flue L. 

f—Slits admitting hot and cold air from L to kiln. 

g—Slits admitting hot air against the gas. 

h—Slits regulating passage of gas from R to Q. 

i—Slits between P and S. 

k—Fire-clay .slabs regulating the entry of hot air from P to Q. 






THE DUNNACHIE GAS-KILN FOR BURNING FIRE-BRKjK, ETC. 3 

covered with a roof as shown in Fig. 2. Under this roof is a 
door, partly of iron and partly of wood, used for the purpose of 
drying the green bricks previous to their being burned. From 
this floor the dried bricks are lowered by a balance-lift to the space 
between the two kilns convenient to the charging-doors. As the 
space betw^een the two sets of kilns below the roof-floor is 20 feet 
wdde by 68J feet long, it gives a room 68J feet long by 60 wide 
heated entirely by radiation, which can be used as a drying floor 
for 2000 bricks a day and can also be utilized not only for storing 
the materials ready to go into the kiln that is being discharged, 
but also for temporarily housing what has been taken out of the kilns. 
The internal dimensions of each one of the chambers are 17 by 
10J feet, and lOJ feet in height, so that each chamber is capable of 
burning from 12,000 to 15,000 bricks, the exact number depending 
upon the size and shape of the brick. Such a kiln as is shown in 
Plate II. is capable of producing 300,000 bricks per month. As the 
entire construction is under a roof, and the space between the kilns 
is high and consequently very light, all the operations of drying, 
charging, steaming, and drawing the charge can be conducted con¬ 
tinuously, the green material being brought automatically from the 
place where it is moulded, and the finished material being dis¬ 
charged from the kilns at the same time to be carried away to the 
warehouses. The operation of charging is going on on one side and 
the operation of discharging on the other, so that there is no waste 
of time in carrying out the operations. 

At one end of these chambers on the outside ^re two producers B 
of any ordinary construction. The gas is carried by a down-take to 
an underground flue E. The producers used at Glenboig can burn 4 
cwt. of a poor slack coal per hour, and give off sufficient gas, with 
the hot-air regeneration by the cooling bricks, to bring the bricks 
being burned up to a white heat. The underground flue E con¬ 
nects by means of alternate flues *R with each one of the kilns. 
To regulate the supply of gas for each kiln, ten valves A, one for 
each kiln, are placed in a straight line in the flue E at the ex¬ 
tremity of the flue B, carrying the gas from the main flue to the 
kiln, so that any quantity of gas may be delivered to any one of the 
kilns independently of the others, or be shut off from them entirely. 
The gas-valves i^^are made of firebrick. They are hemispherical in 
shape, and are bound on the outside with an iron ring. The iron 
stern attached to the hand-wheel by which they ai'e moved is fastened 
by a nut which enters the bottom of the valve about three inches. 


4 THE DUNNACHIE GAS-KILN FOR BURNING FIRE-BIUCK, ETC. 


Tlie liole so left is j)luggo{l with fireclay. The valve-seat is also of 
firebrick. It is placed over the opening in the fine K. The stem 
for moving the valve is fastened to the floor by a cast-iron foot¬ 
plate, in which there is an observation-hole, to visit the valve, which 
is closed with a cast-iron stoi)per. The valve F raised or lowered 
by the hand-wheel A, so as to regulate the supply of gas for combus¬ 
tion. The cold air enters from the openings 0, and /, and L, on 
the outside, which, like the gas valves, can be opened or closed to 
any extent required. On the side of the flue R, and running 
across the whole width of the kiln, are carefully adjusted openings /q 
through which the gas passes in equal volumes and at equal press¬ 
ures, the whole width of* the kiln, Figs. 4 and 5, and enters This 
space ^ is 9 inches wide. The gas meets the air a little below the 
floor-level; thence, as shown by the arrow, it passes into the floor of 
the chamber upon one side. The gas is brought into the burner 
Q through flues 9 inches square, separated by one brick, whose only 
purpose is to strengthen the masonry and to prevent the obstruction 
of the })assage Q. There are fourteen of them in the width of the 
chamber. They are all alike, and extend the whole width of the 
chamber. This space Q is called the burner. In filling the cham¬ 
ber the bricks to be burned are piled close to it, leaving between 
them and the wall of the chamber a space 9 to 10 inches wide the 
whole height of the bricks. The openings from the gas-flue R into 
the burner Q consist of a series of slits /q Fig. 4, which are 4J 
inches wide and the whole height of the gas-flue. There are four¬ 
teen of them which connect with the 9 inch flues that form the 
burner. The middle slits are filled with loose bricks so as to leave 
openings 6 inches high, but the end ones are left full size, so as to 
furnish more gas at these points. The separation between the slits 
/i is a 9 inch brick. It is impossible to regulate exactly beforehand 
the size of these openings. They are, therefore, made much larger 
than is necessary, and are filled more or less with brick, according 
to the indications which are given by the color of the burned bricks. 
Hot air from the cooling bricks is made to pass through the chambers 
in front, and when it is sufficiently cooled, can be made to pass 
into the chimney by means of a damper. By this arrangement the 
gas can be allowed to enter in any quantity to any of the chambers, 
or be entirely shut off from them. The end chambers 5 and 6 
connect with the underground flue M, and the chambers 1 and 2 
with the flue J, Figs. 1 and 4, through 17 slits in the wall of P, 
so that there is a constant circuit of the gas coming from the pro- 


THE DUNNACHIE GAS-KIEN FOR BURNING FlRE-BRTCK, ETC. 5 


(liicers on eitlier side maintained by means of tliis flue. All around 
the outside of the chambers and connected with them on the op]iositc 
end trom the gas are other channels, D and 0, which lead to the 
main chimney, so that the supply of gas and air can always be 
constant, and the draught, with or without pressure, can always 
be regulated in each one of the chambers by means of the dampers, 
exactly as required for the particular phase in which each one of 
them happens to be at the time. The supply of hot air comes in 
through special slits a, Fig. 5, arranged in the floor of the chamber. 
They are all 18 inches long by 2 inches wide, except the end ones 
against the outside walls, which are 2^ inches wide. There are 
twenty-three of them across the chamber. They are controlled by 
valves hj 21 inches long, which work over two rectangular outlets 
m, 15 X 10 inches in size. Figs. 5 and 6, made in the roof of the flue 
P at each end of it. These valves are controlled from the outside 
through the openings /, which, when the furnace is in full fire, are 
closed with bricks laid up dry and plastered over on the outside with 
mortar. The air generally comes through the cooling burnt-off 
bricks two or three chambers behind the one which is burning and 

o 

enters, through the openings m and the slots Figs. 4 and 5, which 
are 3 to four inches in size. There are five rows of these slots, the 
lowest row of which enters the burner Q either at or a little below 
the level of the floor. If a supply of hot air is required higher up, 
it may be brought in hot through the openings A, Fig. 7, which 
are each 21 inches long. They are made in the ends of the flue L by 
moving the damper c, which covers two arched holes N in the next 
chamber, near the end of the flue L, Figs. 4 and 7. Cold air may be 
brought from the outside by closing these dampers and o})ening the 
connections with the outside air at the end of the flue L. The holes 
/, Fig. 4, run the whole width of the furnace. There are four rows of 
them, made by separating the bricks in alternate rows about 2 inches. 
Th is flue L thus serves for the admission both of hot and of cold air 
as well. The air for the ordinary uses of the furnace is brought 
through the bricks which are being cooled down to be regenerated, 
})asses down through the floor of the kiln into an underground flue 
X, of about the same size as the opening R, and from here through 
a series of openings i, Figs. 4 and 7, made in the brickwork into the 
flue P, in the lower part of the dividing wall. From here by means 
of openings in the arches, which are regulated by valves h, Figs. 4, 
6, and 7, it is introduced into a flue 0 above, and discharged as 
shown by the arrows, either a little below or directly on the floor- 


6 THE DUNXACHIE GAS-KILN FOR BURNING FIRE-BRICK, ETC. 


level, against the gases which have come up from the flues upon the 
o[)posite side. The damper /j. Fig. 4, is shown in the drawing on 
the level of the floor of the chamber. It is usually placed a little 
below it, so that there are two of the openings g below the floor. By 
this arrangement the combustion commences in the burner Q a little 
below the level of the floor of the chamber. As the damj)ers give 
complete control of both the gas and the air, any given quantity 
or quality of flame may be produced. The combustion of the gases 
by the hot air produces sheets of flame the whole width of the kiln, 
which pass upward on the side-walls. These walls and the arched 
roof produce a very large amount of radiation, but in order to pro¬ 
vide for complete combustion in all cases, openings are made in the 
dividing walls about half way up. These openings, L, Figs. 4 and 
7, are made for either cold or hot air, which may be made to pass in 
either to bring up or reduce the temperature of the gases at this point. 
If the air is to be cold it comes from the outside; if hot, from the 
burned-oif chamber. This air meets the hot gases from the neigh¬ 
boring chamber, which pass into L through openings iV, Fig. 7, 
made for the purpose. These openings are regulated by the valves 
e, which permit, when necessary, sufficient air to be introduced at 
this point to prevent the bricks from being burned in any one part 
of the chamber at a higher temperature than those in front of them. 
It is not usually necessary, in the ordinary work of the furnace, to 
use these openings N. They are generally used when, for any rea¬ 
son, the fire in the burning-chamber is not hot enough, when the 
hot air from this flue from the chamber next is introduced. When 
the kiln is too hot and there is danger of melting the bricks, cold 
air from the outside is introduced through the same flue. The walls 
of the chamber offer a very large radiating surface. As it is not 
filled uj) to the roof, the space between the charge and the roof also 
permits a considerable radiation, which is utilized for the heat in the 
kiln, and also for the drying-floor above it. As the bricks shrink 
about one-twelfth of their bulk, this radiating chamber, as it may be 
called, increases in size as the bricks are burned. In some cases it 
has been found advantageous to use a blower instead of a high 
chimney, as the gas from the producer generally comes ofl’ at a verv 
slight pressure. When a blower is used, a considerable economy 
may be gained by steaming the green bricks freshlv charo;ed in the 
kiln with air blown through the burued-off bricks, which are no 
longer hot enough for heating the air for combustion, but too hot to 


THE DUNNACHTE GAS-KII.N FOR BURNING FIRE-BRICK, ETC. 7 

be discharged from the kiln. When a chimney is used, unless the 
draught is very strong, this cannot be done. 

The operation of preparing the bricks for firing consists, first, in 
the preliminary tempering on the floor above the kilns and in the 
space between them, so as to drive otf sufficient water to permit the 
handling of the bricks. They still, however, contain a considerable 
quantity of moisture, and it would not be safe to subject them at 
once to a high heat, as there would be danger of their cracking and 
spliting. They are therefore charged into the kiln through the door 
//, and when the kiln is full the door is closed hermetically by two 
rows of bricks laid up dry and plastered on the outside. Hot air 
from the burned-off kilns is turned into them, or, if this is not con¬ 
venient, some gas from the producer, which is ignited so as to give a 
low and gradually rising temperature. During this time of steam¬ 
ing, the stoppers d are withdrawn from the openings in the roof and 
the ])roducts from the heated bricks charged with steam, are allowed 
to escape into the open air. The bricks are not heated to a high 
temperature until all this steam has escaped. During this time the 
two passages G and I remain open. When the steaming is finished 
they are closed. A chimney about 100 feet high is sufficient to 
produce the draught. Stronger draught may be produced by means 
of a blower. The gas leaves the producers at a temperature of from 
600 to 800° Fahr. It is passed into the chambers and there burned 
by the admission of air which has been highly heated by passing 
through two or three burned-off chambers which have been brought 
up to a high temperature, as high as the melting-point of steel. As 
the o])eration is continuous, we will suppose that chambers Nos. 3 
and 4, Fig. 1, have been burned oflP. The gas from the pro¬ 
ducers is turned into chamber No. 5, which has just been steamed. 
Chamber No. 2 is open, and, cooling off, the air is made to pass 
through Nos. 3 and 4, which are burned-off and cooling down. No. 
3 will then be red hot, and No. 4 at a white heat. From No. 4 the 
air descends through the slits, a, Fig. 5, into the flue, N, Fig. 4, 
through the slits, /, to the flue, P, and thence through the rectangular 
openings wq Fig. 5, which are regulated by flat plates of firebrick m. 
Fig. 5, which are controlled from the outside by the slab through 
i, into the flue, 0. This flue is provided with openings, g, which 
extend the whole width of the furnace, and are so calculated as to 
supply the exact quantity of air which is required for the perfect 
combustion of the gas. The rule in this respect is to make the 
capacity of the air opening two and a half times that of the gas 


8 THE DUNNACHIE GAS-KILN FOR BURNING FIRE-BRICK, PITC. 


The combustion commences a little below the level of the floor, 
and extends some distance above it. The air passes through these 
openings into the burner, where it meets the gas coming u[) from the 
flue, Q. Chamber No. 6 'is thus in full fire. It is filled with clear, 
bright flame. The products of combustion are made to jiass through 
No. G, which is called the benefit kiln, before going to the chimney. 
No. G is thus brought u]) to a bright red heat, and, in its turn, when 
No. 5 is burned off, becomes the full fire kiln by turning off the gas 
by the damper A and turning it on to No. G. Nos. 7, 8 and 9 are in 
front filled with green brick in process of steaming ; No. 9 is filling ; 
No. 10 is ready for filling; and Nos. 1 and 2 are being emptied. 
Thus all the operations are continuous: No. 2, open and being cooled 
off‘; No. 3, red hot, No. 4, white hot, both burned ofl and cooling; 
No. 5, burning in full fire; No. G, in the prej)aratory stage to full 
fire; Nos. 7, and 8 steaming; No. 9 filling; No. 10 ready for 
filling, and No. 1 divScharging. 

When the gas is first turned on to No. 5 the chamber No. 2 will 
still be too hot to be discharged, and for the first five or six hours 
the air is made to pass through chambers 2, 3, and 4, to reach No. 
5. After this time the gain would be too small, so that No. 2 is cut 
oft’ although the bricks still retain considerable heat. This is done 
by shoving in the firebrick slab h, which closes the opening m,, so 
that the air no longer passes them. The cold air is introduced by 
taking down the bricks which close the opening I in chamber 
No. 3. During very damp weather and in the winter the heat of the 
chamber corresponding to No. 2 is made use of by introducing a 
square pipe into /f. Fig. 3, and blowing cold air into the kiln. This 
])ii)e connects with another which carries the air thus heated to the 
drying-floors, thus utilizing the heat which would otherwise be lost 
and cooling down the chamber at the same time. The main ])ipes 
are put up permanently, with branches leading to each chamber. 
The ends of these branches are closed when not in use. The move- 
able pi})e fits all the branches. 

In the ])re]iminary heating, which is called steaming, there is a 
very considerable quantity of moisture given off from the bricks, 
which moisture, as it is likelv to absorb a large amount of heat, is 
allowed to esca})e from the openings in the roof d. Figs. 4, G, and 7, 
the stoppers from wfiiich are removed for the purpose. This is done 
by introducing into these kilns a little producer gas, and burning it 
by means of cold air. All the air-})orts and root-vents remain o})en 
during the whole of this stage of the ])rocess, and are only closed 


TFiE BUNNACHIE GAS-KILN FOK BURNING FIRE-BRICK, ETC. 9 

when the cliambers are ready to fire. As soon as the steam oeavses 
to condense in each chamber, the openings are closed, so that 
none of the gas escapes. They are also used when it is desirable 
to cool a chamber quickly. The chamber No. 7 would in this 
instance be called a green chamber, since the bricks in it have not 
been burned. Behind it there would be two—or. as many as three 
—other chambers which were being cooled off, that is, say, 4, 3, and 
2. The temperature in chamber 5 can be increased in 24 to 36 
hours up to a steel-melting heat, that is, to the stage of full firing. 
While this operation is going on, the next chamber in the series will 
receive the gases, so that the bricks in chamber 6 will be dried and 
brought nearly up to red heat. Into this the heat would be passed 
so that the operation would go on in the following chamber in 
exactly the same way. 

In order to burn the brick successfully a white heat is required. 
To maintain this, it is necessary to have the proper admixture of 
gas and air and to keep it at the proper temperature and under 
entire control. Without such control it would be quite possible 
that the temperature upon one side of any one of the chambers 
might be sufficient to melt the bricks, and on the other not sufficient 
to burn them. It is for this reason that the flames are so divided in 
the underground channels, and that fines are made in the upper part 
as well as in the lower. Under these conditions there is no danger 
of unequal heat, or that any ash or other material will be brought 
in with the gas, thus causing danger of fluxing the surfaces of the 
brick and making them rougli. This kiln can be adapted to use 
for many other purposes besides that of making brick. 

In the original design of this furnace the idea was fully considered 
of having each chamber arranged in such a way as to be indepen¬ 
dent of its neighbor, and so that it conld be used, skipping one, 
two, or three chambers, on either or both sides. But the expense of 
construction was so much increased, the complication of the fines so 
great, and the advantage to be derived from it so small, that the 
idea was finally abandoned without constructing any furnaces in this 
way. The wisdom of doing so has been fully confirmed by sub¬ 
sequent experience, for it has been found in actual practice that there 
is am])le time between the burnings for the most serious repairs, 
which fortunately up to this time have not been required. 

The result of this method of burning is a saving of from 50 to 75 
per cent, in the cost of manufacture. This saving is large, but not 
much larger than should have been expected, and results, first, from 


10 THE DUNNACHIE GAS-KILN FOR BURNING FIRE-BRICK, ETC. 


the use of gas and regeneration ; second, from economizing the heat 
in the preliminary stages by using the waste heat to bring the bricks 
up through the ])reliminary temperatures; third, from the use of the 
radiated heat for drying the bricks. This last saving may be still 
farther increased by extending the floor over the bricks 20 feet 
beyond the walls and all around them, which would greatly extend 
the drying s})ace and thus facilitate the work, and still further econo¬ 
mize the heat. Such a construction would about double the capacity 
of the drying-floors above the kiln. The output of the kiln is, how¬ 
ever, so large that some drying-stoves must always be used with it 
as with every other kiln. 

Mr. Dunuachiehas made a series of experiments with the Siemens 
water pyrometer with a copper bulb, to ascertain what the tempera¬ 
ture of the gases escaping into the chimney was : 


Time of 
observation 
after 

4 hours, 

12 ‘‘ 

24 “ 

30 “ 


Temperature of the chimney when 
there was but one chamber of 
green bricks. 

150° F. 

200 ° 

250° 

300° 


Temperature of the chimnej^ when 
tliere were three chambers of 
green bricks. 

90° F. 

120 ° 

150° 

180° 


In making the ob.servations with only one chamber of green bricks 
between the chimney and that in full fire,* the copper bulb could 
only be held in the flue 81 minutes, for fear of melting the wire to 
which it was attached, so great was the heat. But, when there were 
three, it was left for an hour before the temperatures were read. This 
shows, conclusively, the saving of heat and consequent economy of 
the furnace. 


d he average of cost of burning bricks in the old Newcastle kilns at 
Glenboig was 8s. 2d. per thousand. In the hopper kiln, Invented by 
Mr. Dunnachie about 1865, it was 6s. 6Jd per thousand. In the 
present Dunnachie kiln it is 2s. 9JcZ. per thou.sand. The saving in 
fuel effected by the use of these kilns is from 50 to 75 per cent. At 
Glenboig, where everything is very carefully done, it reaches 75 per 
cent. There is also a very considerable reduction in labor and re¬ 
pairs. The product is of better quality and more uniformly burned. 
J his is accomplished mostly because of the simple construction of 
the kiln, which allows of regulating the temperature at any ])hase 
and of having it constant through all parts of the kiln. As the 
floor of the kiln is solid, there being no flues or openings in it except 
at the sides, where they are quite large, they do not break and crack, 
nor do the flues become obstructed with sand or broken brick, as is the 


THE DUNNACHIE GAS-KILN FOE BURNING FIRE-BRICK, ETC. 11 

case witli most other fire-brick kilns. The kilns used at Glenboig 
have been run contimionsly for eighteen months without repairs of any 
kind. As the mixture of gas and air is always under perfect con¬ 
trol, and the passages of the upper part are also regulated by valves, 
the heat may be raised or lowered, according to indications given by 
looking into the kiln from the outside, and is always uniform from 
one end of the furnace to the other, so that there is no breaking 
from sudden or unequal heating, and almost no hard or soft bricks 
are produced. 

The output of these kilns is almost double that of the old kilns, 
the capacity being the same, but only half the time being required to 
burn in the new ones. The cost of a set of ten chambers with two 
gas-producers, arranged as in the drawing, is from 1500 to 1600 
pounds sterling, for kilns having the capacity of 300,000 bricks per 
month. I am indebted to Mr. Dunnachie for the following esti¬ 
mates of the construction of both kilns. The data are given in 
English money, which can be easily converted into dollars and 
cents by counting the pound at $4.84 and adding the price of ex¬ 
change.* The cost per thousand bricks, using a good quality of 
coal, was in September, 1885, in the Newcastle kiln 8s. 9d., and in 
the Dunnachie kiln, using a cheap slack, 2s. dd. for the best quality 
of Glenboig bricks. For those of a lower quality, which are required 
to stand less heat, the cost would be very much less. The rej)ntation 
of the Glenboig brick is such that only first-class bricks are made 
there. 

4 he labor in the o;as-kiln is much less than in the older ones. 
As the men are not constantly employed with the kilns, the work is 
less fatiffiiinp;', and the number of workmen can be very much re- 
duced, when these furnaces take the place of the old kiln. In most 
of the works where this kiln has been constructed, it works side by side 
with the old kiln, so that the men are busied sometimes with one 
and sometimes with the other. The kilns are burned off about 
three times a month. The time that the bricks are in the new kiln 
is as loim as in the old one, since they are used for regeneration; 
but there is greater economy in this, since all the heat stored np in 
them is utilized instead of being lost as before. The steaming stage 
lasts four shifts of twelve hours each, or forty-eight hours in both 
kilns. The full-fire stage takes from four to six shifts, or from forty- 

* The cost of the pound sterling varies generally, in New York, from |4.90 to 
$4.96, depending on the rate of exchange. In making preliminary estimates it is 
best to count $5.00 to the pound. 



12 THE DUNNACPIIE GAS-KILN FOR BURNING FIRE-BRICK, El'C. 


eight to seventy-two hours, in the old kiln, and two to three shifts, or 
from twenty-four to thirty-six hours, iu the regenerative. The heat¬ 
ing and cooling are much more gradual in the regenerative than in the 
old kiln, and consequently there is less deterioration in the material 
manufactured. In the Newcastle kiln, it is necessary frequently to 
open the doors while the brick is almost at a white heat, thus cooling 
those which come in contact with the air and reducing the temperature 
of the kiln at times very greatly. In the regenerative kiln, the doors 
are hermetically closed at the commencement and remain so until 
the end. In the Newcastle kiln the air is full of smoke from the 
incomplete combustion of the fuel, while in the regenerative kiln 
the combustion is so perfect that at the point where the duty begins 
the carbon is all burned, and there is no smoke at any point when 
the kiln is properly worked. Ordinary laborers can learn to work 
the kiln with great ease, because what is going on in the interior 
of every kiln can be seen from the outside, through the spy-holes 
made for the purpose in the built-up door of the kiln. These are 
closed when not in use with a fireclay plug. The gas and air are 
regulated so as to have a clear flame from one chamber to the other. 
The moment any smoke is seen either in the chambers or in the 
chimney top, perfect combustion can at once be secured by opening 
or shutting the proper valve. 

The drawing, Plate I., of a })air of Newcastle kilns shows the 
method of firing and the size and general disposition of the kiln. 
As compared with the regenerative kiln it will be seen that the con¬ 
struction is not much more simple, while the holes in the floor, as 
shown in the drawings, make the furnace much more difficult to 
manage. The number of bricks used iu each furnace is about the 
same, and the cost of construction is not very different; so that there 

w / 

is every advantage in using the regenerative kiln. 

specification of Materials Re(piire(l for One Set of 10 Chambers of 
Ihnmachie’s Continuous liegenerative Gas-Kiln. 

Excavations : 

(hitting for Foundaiiom of Kilns, alloieing for Scarcements ; 

08x42x3} feet=:352} cubic yards. 

Flue round outside of Kilns: 

272x4.2x3^ feet=1492 “ 

Main Gas Flue between Kilns: 

00x5x5 feet= 55^ “ 


557} ] s. per yd., £27 17s. OOd. 


£27 17s. OOd. 




13 


TFIE DUNNACHIE GAS-KILN 


FOR BURNING FIRE-BRICK^ P7rc. 


* Bricks 

Used in Building Set of Kilns, including Flues: 

Square bricks, 9xUx3 ins.,. 293,000 

For Croirns: 

End arch bricks, 9x4^x3-x2^ ins., . . . 37,000 

For Flues, Etc.: 

Side bricks, 9x42x3 and 2 ins., .... 30,000 

Horse blocks, 24x9x7 ins., . 250 

Between Horse Blocks: 


Scone bricks, 9x44x2 ins., ...... 450 

For Steaming Holes: 

Covers, 18x12x3 ins.,. 250 


360,950 

Abstract of Vahic of Bricks: 

260,450 bricks (1st quality), 40s., . -. . 
100,000 bricks (2d quality), 20s., . . . 

250 horse blocks. Is. 6d. each, . . . 

250 covers, 9d. each,. 


£520 18s. OOd 
100 00 00 
18 15 00 
9 07 06 


£649 00s. 06d. 


Building 

Of one set of Kilns (Labor ): 

£17 for each of 10 chambers. 


. £170 00s. OOd. 


Woodwork : 

Centres and cleading used in building 
crowns of kilns—three sets reiiuired at 
once, at £6 each set,.£18 00s. OOd. 

Ironwork : 

Kiln Binders: 

24 cast-iron upright binders, 13 ft. long, 

12J cwt. eacli = 14 ton 14 cwt., £5 2s. 

6d. per ton,.£75 06s. 09d. 

20 cast-iron cross binders, 12 ft. 3 in. long, 

9 cwt. eacli — 9 tons, £5 2s. 6d. per ton, 46 02 06 

12 malleable iron binding rods, 21 ft. long, 
by Ij ins diam., 13} cwt., 6s. per cwt., 3 19 06 


£676 18s. OOd. 


£170 00s. OOd. 


£125 08s. OOd. 


Capcicify if Kilns : £990 06s. OOd. 

10 chambers, each containing 14,000 bricks, 

9x42x2} ins., 140,000. 


Specifications of 31aterials Required for the JJrping-stove above the 

Gas Kilns. 

Wrougiit-iron Girders. 

For tons of Columns: 

6 girders 13^-0}^^ long J ! 

2 girders 13^-6'^ long “ | t. cwt. 

2 girders 12'-4^'long ‘‘ J =18 £6 [>er ton. £8 8s. Od. 


* Of the above quantities, about 100,000 may be bricks of second quality for packing, butts and 
between arches, etc. 















14 TPIE DUNNACHIE GAS-KILN FOR BURNING FIRE-BRICK, ETC. 


Between kilns: 

■] 

6 crossgird’rs 20 '- 0 ^^ long | 

14 “ “ 13'-6'Mong ^ 

S" 

14 “ 12'-4'Mong “ 

42 “ “ 13'-0'^!ong “ 

Cast-iron Plates for Floors: 

o72 plates 4'x2'x|'' thick, lAd. each, 
Wood Floring between Kilns: 

800 linealfeet joisting 62 ^^x 2 - 2 ^^, 

110 square yards flooring, 


= 2 6| 

--= 4 7| 

= 27 18 £4 5s. [), t. 


Id. per foot. 
Is. Id. }). yd. 


14 Os. 6d. 


26 6s. 6d. 

118 11s. 6d. 

3 6s. 8d. 
5 19s. 2d. 


£176 12s. 4d. 


Specification of Materials Reqidrerl for Six Neiccastle Kilns (in jniirs). 

P7xcavatjons : 

Cutting for Foundations of Kilns: 

34x30x4§ ft., each pair for 6 kilns, 507 c. yds. 


Cutting for Butts: 

For 6 kilns,.79 “ 

Fines outside of Kilns : 

Average distance from kilns to 
chimney,. 1492 “ 


7352 Is. per yd., £36 15s. 06d. 

*Bricks 

Used in Building Six Kilns. 

For Side-Centre Walls : 

From foundations to si)ring of arch, square 

bricks, 9x41x3 ins.,. 45,080 

For Flues 

Inside of kilns, and flues outside of kilns 

to chimney, 9x41x3 ins.,. 40,000 

For Ci'owns: 

End arch of square bricks,. 53,280 

For Bind Walls: 


Square bricks,. 55,200 

For Butts: 

Square bricks,. 105,000 


B'or Bloors of Kilns : 

Packing between arches and causewaying 

for fuel, square bricks,. 35,650 


£36 15s. 06d. 


334,210 

Abstract of Value of Bricks: 

234,210 bricks (1st quality) 40s. per 1,000, £468 OSs. 05d. 

100,000 bricks (2d quality) 20s. “ 100 00 00 

-£568 08s. 05d. 


_ £605 03s. lid. 

* Of the above Quantities, about 100,000 may be bricks of second quality for packing butts 
and between arches, etc. 


















THE DUNTviACHlE GAS-KILN BX)R BURNING FIRE-BRICK, ETC. 15 


Building 

Of Six Kilns. (Labor): 

Cost of building per rood, equal for gas or 

Newcastle kilns,.£170 00s. OOd. 

W OOD WORK : 

Centres and cleading for two chanihers, 

£9 each set,.£18 00s. OOd. 


Ironwork : * 

Kiln Binders: 

18 cast-iron upright binders (6 to each 
pair of kilns), 12] cwt. each ~ 11 tons 
1 cwt., £5 2s. 6d. per ton,.£56 10s. Old. 

12 cast-iron cross binders (4 to each i)air 
of kilns), 10| cwt. each = 6 tons 3 cwt., 

£5 2s. 6d. per ton,. 31 10 05 

9 malleable iron binding rods, 34 ft. long 

lo ft. diam., 16 cwt., at 6s. per ton, . . 4 16 00 


£170 00s. OOd. 


£18 00s. OOd. 


£92 16s. 06d. 


Capacity of Kilns: 

6 kilns, containing in the aggregate 140,- 
000 bricks, 9x42x24 ins., 140,000. 


£886 00 05d. 


It is well to have the floor of these kilns on the same level with 
the floor of the drying stove, both of which should be about one foot 
at least above the ground level outside, to prevent water entering. 
The amount of excavation will depend on the ground level. 

The depth of flues inside the kilns is 4 feet from floor, and the 
flue bottom is a brick on edge, so that the whole depth from kiln 
floor to bottom of excavation is 4 feet 4J inches, say 4J feet, Imt as 
the floor is one foot above the ground level, the excavation will be 
only feet deep. 

The expense of filling, cooling, and emptying is the same in gas 
kilns as ordinary kilns, viz., for filling l,s*. 3d. per 1000 bricks, and 
for emptying, 9d. per 1000 bricks. The expense for firing is also 
the same in both cases. One man takes charge of a set of ten 
kilns, having full charge of gas-making and brick-burning. In 
the regenerative system one kiln is always in full fire, and one is 
always rising to it by the spare heat of the burning kiln passing 
through it. There are also two steaming kilns ahead of the burning 
kilns, preparatory to the higher heats, the gas and air in this case 
passing in direct, as high heat is not wanted at this stage. 


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TrMsactioiiis of tie Amerieaiii iMstitnite ef Mimiiig EnigiMeers. ¥eL XV. 




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DUNNACHIE’S 

PATENT 

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SCALE 10 Ft.=^'1 IN. 


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